PREPRESS COMPETENCY IN NEWSPRINT // EXPERTISE IN WEB PRINTING

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1 EN PREPRESS COMPETENCY IN NEWSPRINT // EXPERTISE IN WEB PRINTING

2 HIGHLY EFFICIENT PREPRESS SOLUTIONS FOR EVERY NEWSPAPER

3 HANS-HEINRICH BENECKE PREPRESS ENGINEERING/ SALES JOCHEN GLÄSER PREPRESS ENGINEERING/ SALES The optimal solution is always based on a proper requirements analysis. Concise expertise at marks-3zet For many years, Hans-Heinrich Benecke and Jochen Gläser have worked for manufacturers of prepress systems, both in the areas of project management and sales. They are aware of the requirements for a modern prepress infrastructure, including the current technical possibilities and the products of various manufacturers. Their competence provides customers with comprehensive advice, taking into consideration the existing production situation as well as individual requirements of the customers to efficiently realize company goals. What you can expect from us Every company is different at heart, has its own objectives, an individual customer and order structure and special requirements. That is why we do not install any off-theshelf systems but opt for manufacturer-independent solutions. This means that, as a general contractor, we offer you an all-around package from consulting to installation and commissioning of all components. We provide all services for an agreed project, ranging from the handling of communication with manufacturers to the coordination of the installation process, including the final acceptance procedure for a total solution. Our project services also include the development of training plans for your staff. We are your one-source contract partner and undertake full responsibility for all deliveries and agreed services. When searching for a suitable prepress solution, we focus on your requirements. We will provide consulting on how a modern, integrated newspaper production can be achieved in your company. Pivotal to all considerations and decisions is the prioritization of the customer s requirements. PREPRESS SYSTEMS MUST FIT The marks-3zet experts have made quite a name for themselves in Europe and overseas, with the installation of prepress systems for newspaper printing. After a suitable solution for your company has been developed, its implementation will be carried out in the following steps: // Creation of a specification document // Space planning // Planning of the utility connections // Description of the interfaces needed for an efficient workflow // Scheduling // Planning of staff training // Project management during on-site installation of all components // Final acceptance procedure for the overall solution // Production support

4 PQM plate quality management Depending on requirements, an automated quality management system can also be integrated Exposure machines Correspond to customer requirements and are based on the demands regarding the CTP system Punching and folding systems Defining priorities regarding costs or performance capabilities; 1- or 2-unit machine CTP systems Prioritization on quality and/or speed; integrated or semi-automated Plate sorting facilities Modern sorting concepts with dynamic, just-in-time availability as well as systems for decentralized sorting can be implemented INDIVIDUAL SOLUTIONS WITH STATE-OF- THE-ART COMPONENTS Many different components are required for an integrated production of newspapers. marks-3zet is manufacturer-independent, offering more freedom of choice and an enhanced production reliability. Workflow for the control of CTP lines // The link between publishing house and printing plant // All operational steps from layout up to the finished printing plate // Manual or fully automated operation mode // A determining factor for the quality of your printing plates Softproof color validation // Pure information or the basis for a production release // Support for production managers // Is, however, only as good as the workplaces where it is applied

5 from initial analysis to final acceptance procedure, we like to rely on our experience! ROLAND NEIGENFIND, MANAGER OF PLANNING AND SALES OF PREPRESS SYSTEMS, IG (R), PATRICK SPAHR, OPERATIONS MANAGER FOR MDS, JOCHEN GLÄSER, PREPRESS SALES AND PROJECT MANAGEMENT (L) Before after Group-owned subscription newspapers, such as Kölner Stadt-Anzeiger, Kölnische Rundschau and EXPRESS, are printed in the Cologne printing plant of the Media Group M. Dumont Schauberg. Also a number of third-party products are printed here, such as advertising journals and various promotional brochures. For project planning and installation of the entire prepress line, DuMont decided to rely on external experts. It soon became clear that Illies Graphik, the previous employer of Mr Benecke and Mr Gläser, was the most suitable partner, since this company disposes over decades of experience in the installation of prepress systems in the newspaper industry. Realization In the year following the final go-ahead, three complete plate exposure lines were installed, including state-of-theart CTP exposure units working with thermal technology. Process control was managed by a semi-automated plate quality management (PQM) system, including process monitoring and an early warning system for operators. The team developed a linear machine concept, with very short production paths that permit maximum monitoring. A further increase in productivity was achieved through an automated sorting of printing plates. Facilities for remote monitoring, which include visualization of the status of automated plate production, provide a maximized overview of the current status. Last but not least, remote access including remote maintenance functionalities reduces downtimes in case of a failure. Implementation steps Mr Gläser and Mr Benecke took complete responsibility for the realization of this project and carried out the following steps: // Planning of the building in coordination with the architect and representatives of the building contractor // Definition of the spatial conditions, the supply paths and utility connections // Coordination of deliveries, forklift services and transportation // Project management during installation by the suppliers (Kodak, Nela, marks-3zet and ppi-media) Initial situation in 2008 // Six plate development lines were distributed over the entire surface of the production area. // The company was working with flatbed CTP exposure units using violet laser diodes, which had a relatively high energy and chemicals consumption, and violet plates that needed to be processed under yellow light. // The customer was looking for a smart concept for the automation of prepress procedures. Process stability and a continuously high output quality had to be ensured. Furthermore, plate sorting also needed to be integrated in this concept. GOOD EXAMPLE Our specialists have decades of experience as a service provider. We deliver complete prepress lines to various German, European and overseas newspaper publishing houses, including M. DuMont Schauberg in Cologne.

6 AN INTERVIEW WITH JOCHEN GLÄSER AND HANS-HEINRICH BENECKE automatic test and reliable plate exposure, all of which are preconditions for a smooth production. Within the process, the status must be automatically detected and the corresponding information must be distributed to the appropriate locations. Of course, the prioritization of orders is of equal importance, so that the rotary presses are optimally used and orders can be produced on time. Another important and a new aspect for newspaper printing plants is the archiving of printing jobs. // What are the demands on the workflow? Processing of different data formats, such as EPS, JPG and TIF, are an absolute must in semi-commercial printing. Thus, printing data need to be examined and adapted to allow printing down to a 80s grid print. Furthermore, it is also best to carry out fully automated positioning and imposition on the plate in order to ensure high productivity. The resolution is based on the settings that have been defined for the type of printing job. Here it is important to observe both the process stability and quality requirements of the customer. After all relevant information, such as plate identification with barcodes and marks, has been added for the print job, a softproof and a printed proof are those with the highest process stability. Exposure units with violet laser diodes, however, work at a higher speed and are usually more cost-effective. So the decision here must be based on a prioritization of requirements. // What has to be taken into consideration regarding plate handling? As in all other areas, customer requirements are decisive, as well as the spatial possibilities on site with regard to the stacking and sorting facilities to be used. Depending on the type of orders and the available production capacity, solutions can include simple stacking facilities, all the way to automated sorting that provides storage position display. // Process control and quality assurance are playing an increasingly important role in ensuring stable production. What are the possibilities here? Different manufacturers are offering systems that manage the centralized monitoring of all prepress equipment and all integrated components, which are visualized on screen. Changes in status and failures are therefore always displayed im- INTEGRATED NEWSPAPER PRINTING: A MUST OR PURE LUXURY? A strong predatory competition from digital media, smaller print runs, an increased number of semi-commercial print products and higher quality requirements are defining the daily routine of newspaper printing plants today. This development has exerted a strong influence on the demands laid on prepress systems. // Mr Benecke, what aspects in the area of prepress are the precondition for a modern newspaper production? handle this process as efficiently as possible, data processing, print plate production and plate handling must be perfectly matched to one another. sent to the customer for release. Finally, plate production is carried out on the basis of production planning. mediately. This technology is highly recommended, since the reaction time in case of malfunctions is decreased and productivity increases. Due to the production mix that consists of newspapers and semi-commercial print products, newspaper printing plants are continuously exchanging data with their customers, such as the publishing houses and the editorial offices. Consequently, they must handle the receipt, examination and printing of these data. To be able to // Which specific requirements arise for prepress handling? In the field of prepress, the aim is to automate all workflows to such an extent that maximum productivity can be achieved. This starts with the external data that is received and proceeds to an // Mr Gläser, let s focus on plate production: What do the customers have to pay attention to when selecting a system? The basis for the selection of an exposure system is an analysis of customer requirements. In principle, thermal plates are today considered as // Many thanks for this interview!

7 marks-3zet: Introduction of an expert. marks-3zet was founded in 1873 and developed from a leading industrial-scale printer of the Ruhr area of Germany into a leading supplier of calibrated substrate sheets, waterless offset printing facilities and CTP prepress systems. Since 1982, marks-3zet is the official sales partner for waterless offset printing equipment. The technology for directly adding pictures to the print plate, which was new back then, was immediately integrated by marks-3zet in 1998, which began to offer waterless CTP printing plates on the market. Due to customer demand, the development of this technology continued and has established itself with newsprint providers since Since then, numerous quality and environmentally conscious newspaper publishing houses have discovered the advantages of waterless offset printing and have opted for equipment that was especially developed for newspaper rotary printing presses. Due to this success and progress resulting from our experience, marks-3zet is also presenting high-end CTP prepress solutions for demanding wet-onwet printing applications. Besides individual solutions such as printing plate imaging systems, fully automated plate development, plate transport and sorting systems, marks-3zet also offers consulting on turnkey projects for industrial newspaper production associated with new or reinvestments. 07/ bozs.de Mitglied der marks-3zet GmbH & Co. KG Lahnstraße 38 D Mülheim an der Ruhr Tel. +49 (0) 208 / Fax +49 (0)208/ info@marks-3zet.de

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